Surface construction for walls and the like



Oct. 15, 1940. F G DRESSER -SURFACE CONSTRUCTION FOB WALLS AND THE LIKEFiled May 22, 1.939 2 Sheets-Sheet l x I 7 1/ 0 W INVENTOR.fiairlfiresaer Oct. 15, 1940. F. G. DRESSER SURFACE CONSTRUCTION FORWALLS AND THE LIKE Filed May 22, 1959 2 Sheets-Shet 2 1N MENTOR F/dii/i/zisar BY% M ATTORNEY Patented Oct. 15, 1940 PATENT OFFICE SURFACECONSTRUCTION FOR WALLS AND THE LIKE Frank G. Dresser, Providence, R. L

Application May 22, 1939, Serial No. 274,893

Claims.

This invention relates to improvements in surface constructions forwalls and the like. More especially it has to do with a new type ofplate-like construction units andsupporting and retaining means thereforwhich may be employed for surfacing sidewalks, roads and exterior wallsof buildings, but which are particularly appropriate for use interiorlyof buildings, for surfacing walls, floors and ceilings.

The invention is herein disclosed as embodied in the construction of aninterior wall of a building, but it will be obvious that the structuralfeatures hereinafter disclosed have general application where aninexpensive, permanent and attractive composite-block surface isdesired.

It is among the objects of the invention to provide plate-likeconstruction units which may be combined to produce a hard, durable andattractive block-surface. The face of these units may be suitablycolored togive the appearance of ceramic tile, but the dangers ofchipping, cracking, or discoloration inherent in such tile are entirelyavoided in my construction. This follows from the fact that myimprovedplateform units may be made of metal and hence will be non-cracking andpractically non-marrable in use. Moreover a surface composite of theunits can be much lighter in weight and have more durability thanceramic tile.

Further objects are to provide means on each unit for effectivelyanchoring the units in plaster, concrete or the like, and to provide apre-formed metal web which constitutes a support both for the plateunits and for the plaster or like substance, thereby eliminating theneed for the usual back-boards or lathing.

These objects may be attained by providing rectangular plate units ofsheet metal, of any suitable area, which may be arranged edge to edge inrows across and along the structure, or may be staggered if desired.Preferably these units will be of galvanized iron faced with aluminum,and the exposed surface of the latter may be oxidized to produce anextremely hard surface with attractive color effects.

The units have means projecting from their rear sides constitutingspacers for spacing the units from a web support, and serving also asclinchers around which plaster or the like may engage for anchoring theunits in place.

The web support may be of sheet metal preformed to have multipleparallel ribs extending at right angles to the base plane of the web. Inthe case of an interior wall, the web, of size to extend over aconsiderablesection of Wall, may be nailed to the usual studding, withthe ribs projecting in a horizontal plane and constituting shelves forsupporting plaster which will be packed therein behind the plate units.The spacers of the units rest on the outer edges of the ribs. Preferablythere will'also be spacing lugs on two adjacent sides of each plate-unitfor providing crevices around each unit, which may be filled withplaster or cement to attain a desired plaster-like effect.

It is intended that the patent shall cover, by suitable expression inthe appended claims, whatever features of patentable novelty exist inthe invention disclosed.

In the accompanying drawings:

Figurel is ayperspective illustrating interior walls of a building, asif in the course of construction, and showing a wall structure embodyingfeatures of my invention;

Figure 2 is a perspective of a flat sheet of metal, perforated andadapted to be formed into my improved ribbed web support;

Figure 3 is an elevation insection through a wall embodying features ofthe invention;

Figure 4 is a plan in section on 44 of Figure 3;

Figure 5 is a perspective of the face portion of one ofmy surface units;

Figure 6 is a perspective of the lining portion which fits within theface portion of Figure 5;

Figure '7 is a sectional View through a completed surface unit on a lineextending through two of the spacers;

Figure'8 is a perspective showing a surface unit formed for a cornerlocation;

Figures 9 and 10 are perspectives showing the section of a liningportion which may be employed for a corner unit like that of Figure 8;and

Figure 11 is an edge elevation of another surface unit suitable for acorner.

Referring to the drawings, and more particularly to Figure 1 thereof, mypre-formed supporting web I6 is shown nailed to the usual studding l2 ofa wall structure, each section of web being preferably of size to spanseveral spaced apart studs and being of any desired and predeterminedarea. Preferably, a section of web ata corner location will terminate ator close to the corner, and a like section of Web, on the other wall,will extend to meet or to closely approach it at the corner.

Each web section may be formed of suitable sheet metal, such asgalvanized iron for example. Before the web is formed, the flat sheet ofmetal,

as represented in Figure 2, may be punched with holes M, which arearranged in rows and spaced at precise predetermined intervals apart.Then, in any suitable way, or by any suitable means,

I the sheet is bent and foldedinto its web form of Figure 1, whereinmultiple ribs l6 extend in spaced parallelism, and each projects atright angles to the plane of the base I8 of the web. In Figure 2, thedotted lines l5 indicate the lines of bending or folding in theformation of the web, and it will be observed that pairs of the holes l4register together at the ribs l6 so that plaster retaining rods or wiresl9 can be thrust through the aligned holes so as to cross any de-" sirednumber of the valleys 20 between ribs. The web I0, with the plasterretaining rods l9 extending through its ribs and across the valleysbetween ribs, at suitable spaced locations along each web section, makesunnecessary the use of back-boards and lathing, because plaster 22 orthe like is effectively supported against sagging by the ribs l6, and isretained in the valleys of the Web by the retaining means l9.

My improved plate-form surface units 24, 26 may be made of any suitablestrong material but, preferably, will be of galvanized iron, faced withaluminum. In a preferred form, as shown in detail in Figs. 5 to '7, eachunit 24 comprises lining portion 28 here shown as a rectangular, flangedplate. This may be made of galvanized iron, or other suitable material,and in the case of galvanized iron, a thickness of sheet of .015 to .020of an inch will suffice. Such a lining 28 may have spacers 30 securedthereon, or, preferably, punched out of its sheet body, to project fromits rear side for resting on the edges of ribs I6 of the web, and to beburied in the plaster which is between the web I and surface units. Eachsurface unit comprises, in addition the lining portion 28 face portion32. This is also illustrated as of flanged rectangular shape and. sizeto fit over the outer face and edges of the lining 28. Preferably theface portion will be of aluminum, and if so, sheet aluminum of .020 ofan inch in thickness will be adequate, because the face portion isstrongly reinforced by the galvanized iron lining 28.

As seen in Figures -7, the flange ofthe face portion 32 may be formedwith a plurality of tongues 34 spaced along the edge of flange at eachside of the element. Some of the tongues at each side, after the face isplaced over the lining 28 may be bent inward over the flanged edge ofthe latter, to secure the face and the lining together. Others of thetongues, preferably on twoadjacent sides of the unit, may be bentoutward for engaging adjacent units and thus constitute spacers forproviding a crevice 36 between adjacent units. The crevices may befilled with plaster or cement after the units are mounted, to provide adesired plaster line effect around each unit.

Figure 8 represents an angular unit suitable for corner locations. It isessentially the same as the other units except that the flanges of thelining and face portions are notched as at 38, 40 to facilitate bendingof the units to the illustrated angular shape. Preferably, if aone-piece lining is employed, zinc will be used instead of galvanizediron for the lining, because it is more easily worked. However, asindicated in Figures 9 and 10, a lining of galvanized iron in twosections conveniently may be provided for the corner units.

It will be obvious that there should be a predetermined definiterelationship between the spacing of the ribs l6 of the web and the sizeand spacing of the spacers 30 of the units, so that the spacers will, inevery case, come in position to rest on the edges of ribs I6, therebyensuring that the faces of the units will be in a common plane.

Although plaster is mentioned as the substance to be packed between theweb and the surface units, any suitable substance may be employedwithout departing from the scope of the invention, and the use of theterm plaster in the claims should be regarded in the broad sense ofincluding any substance capable of serving the purpose of plaster in theclaimed combination.

I claim as my invention:

1. A surface construction unit, comprising a lining portion of strongand stiff metal, and a flanged face portion of metal adapted to providea hard and attractive surface, said lining portion being of shape andsize to fit within the flange of the face portion and having spacers atits rear side for resting on a support and for anchoring the unit in;place, and said face portion having tongues on its flange, engageableover the lining. portion, for securing said portions together.

2. A surface construction, unit, comprising a lining portion of strongand stiff metal, and a flanged face portion of metal adapted to providea hard and attractive surface, said lining portion being of shape andsize to fit within the flange of the face portion, and having spacers atits back side for resting on a support and for anchoring the unit inplaster, and said face portion having tongues onits flange, some ofwhich are bent inward over the lining portion for securing the portiontogether, and some of which are bent outward for engaging adjacentunits, thereby to attain a predetermined slight spacing apart ofadjacent units.

3. A surface construction unit, comprisinga flanged lining portion ofstrong and stiff metal, and a fla'ngedface portion of aluminum, saidlining portion beingofshape and size to flt within the flange of theface portion and having a plurality of spacers punched from its body andprojecting at its rear side for resting on a support and for anchoringthe unit in plaster, and said face portion having tongues on its flangeengageable over the flange of the lining portion, for securing theportions together.

4. A surface construction unit, comprising a lining portion of strongandstiff metal, and a flanged face portion of metal adapted to provide ahard and attractive surface, said lining portion being of shape and sizeto fit within the flange of the face portion and having means at itsrear side for anchoring the unit in place, and said face portion havingtongues on its flange, engageable over the lining portion, for securingsaid portions together.

.5. A surface construction unit comprising a flanged face portion ofrelatively thin light metal adapted to provide ahard and attractivesurface, a lining portion of strong'and stiff metal backing said faceportion, being of shape and size to fit within the flange of the faceportion and having means integral with and outstanding from its rearside for resting ona support and for anchoring the unit in place, andmeans securing said elements together to form said unit.

FRANK G. DRESSER.

